Absorbent article including superabsorbent yarn

ABSTRACT

The present invention discloses and claims an absorbent article which utilizes an absorbent portion that includes superabsorbent yarn as part of the absorbent portion, such that liquid is wicked to the perimeter or select regions of the absorbent portion, or the perimeter of the absorbent article itself, taking full advantage of either the depth, width, length or combination of dimensions of the absorbent portion, or absorbent article. The superabsorbent yarn can be one or more of several types, including encapsulated yarn, multilayered encapsulated yarn, coated yarn and sliver-formed yarn as long as such yarn includes at least two components, those being a superabsorbent polymer and a second material which promotes distribution of liquid along the yarn length. In alternatives of the invention, such absorbent article utilizing the superabsorbent yarn provides passive visual signals to consumers, of article saturation levels prior to leakage.

PRIORITY

This application is a divisional of U.S. patent application Ser. No.13/716,912, filed on Dec. 17, 2012, now pending, which claims thebenefit under 35 USC 119(e) of U.S. Provisional Patent Application No.61/577,403 filed on Dec. 19, 2011. The contents of all of the aboveapplications are incorporated by reference as if fully set forth herein.

FIELD OF THE INVENTION

The present invention is generally directed to absorbent personal carearticles. In particular, the present invention is directed to absorbentportions of personal care articles which assist in absorbing and wickingfluids across various dimensions of the articles.

BACKGROUND OF THE INVENTION

The present invention is directed to absorbent articles and inparticular, personal care absorbent articles utilized to collect andretain body fluids, liquids, or exudates including, but not limited tourine, feces, menses, and wound-released fluids, such as blood or pus.In the context of such products, comfort and absorbency are two mainattributes and areas of concern for the wearer. This is particularlytrue with child care, adult care and feminine care products such asdiapers, incontinence articles, feminine hygienic pads, liners andtampons. Less so with wound care articles, paper towels and wipes, butsimilar needs exist for bandage materials.

In the personal care area, large portions of the absorbent capacity ofabsorbent articles have often been free of soiling at the time ofproduct disposal, thereby depriving consumers of the full value of theseproducts. Such inefficient usage of a product is often visually apparentto a user as fluid staining occurs in only a limited area on theproduct. Such inefficient usage of a product may lead to consumerfrustration, as a consumer may infer that the product failed to capturemuch waste, led to a leak, or at a minimum, did not provide sufficientvalue to justify the expense. Therefore, in the personal care area,numerous absorbent structures have been developed for efficientlyutilizing larger areas of the absorbent portion of the articles. Forexample, multiple absorbent layered structures have been employed inarticles (one layer stacked over another) to help transfer liquid ordistribute liquid to larger areas of absorbent layers positioned beneatha liquid entry layer. However, in such layers, if structures withimproperly matched capillary features or improperly placedsuperabsorbents are used, liquid may have a tendency to be blocked inmovement in one or more directions, such as through gel blocking (forsuperabsorbent sheets) or misaligned capillary action, withindensity—gradient, layered structures. If such absorbent materials arenot efficiently used, large areas of the absorbent article are devoid ofwaste at the time of article disposal, thereby failing to take advantageof the potential overall absorbent capacity of the article.

Despite various designs in the absorbent art, there is still a need foran absorbent article/product which when worn, takes full advantage of anabsorbent structure to reduce leakage, and which is relatively thin andflexible for ease of wear in a consumers undergarments. Such a thin andflexible product would also provide relative discreteness, an attributethat is also desired by consumers.

Even when article absorbent cores are functioning, such cores have apropensity to leak at certain locations on a product (depending onproduct type and user habits). Such leakage may cause frustrating andembarrassing staining of a users under or even outergarments. Whilevarious systems have been developed to signal a user of an impendingleak or saturation of an absorbent article, such signals are oftenconveyed using chemical or physical communications such as temperaturechange, scent change, print change upon product saturation oralternatively, embossment marker features. In such “signal” products,additional costly chemistries are needed to convey the message to theuser, or alternatively, the user may have to remove the product, stepoff of the product, or out of the product, to see the signal. Ittherefore is desirable that “signal” products be developed by which auser could casually observe without use of additional chemistry (such asfor example traditional “wetness indicator” technology), or productremoval or special movements, so as to view a signal of impendingleakage. There is also a need for feminine hygiene articles that allow aconsumer the ability to see that such products are working throughouttheir lifecycle, so as to afford a sense of security and emotionalcomfort to the consumer.

Braided absorbent yarn-like materials have been used in connection withpersonal care articles, and such have been known to includesuperabsorbent polymers. However, use of such braided materials has beenlimited to specific projection-like structures for capturing moisturefrom crevices associated with a users body. Such braided structures canfor example, be seen in US20090312729 to Roche del Ayala and arepositioned outside the main body of a personal care absorbent article.

Absorbent yarn materials have been described for use in personal carearticles in conjunction with traditional absorbent sheets for retentionof fluids. Such for example may be found in US20030088229 to Baker.However, such reference does not describe the use of superabsorbentyarns in-and-of themselves, as the sole basis of absorbentcores/portions of absorbent cores. Further, such reference relies onspatial channels between yarns to move fluid to the periphery ofabsorbent core structures.

Superabsorbent containing spun filaments (as opposed to yarn) in whichsuperabsorbent is encapsulated by fluid permeable material, have beentaught and suggested for use in personal care products. Such for examplewas disclosed in US20050130540 to Crane. While such filaments have beensuggested for use in absorbent cores of personal care products, the useof such filaments have been described in sheet-like layers, whichutilize large amounts of material in a non-targeted/inefficient fashion.Transport of such absorbent sheets is often cumbersome. Absorbent sheetsmay also be stiff and subsequently add stiffness to the absorbentproduct. Such usage may be wasteful and expensive, and may impact aproduct's bulk, flexibility, and breathability, physical attributes thatare of particular sensitivity to the women who use feminine hygieneproducts. In this regard, see also US Pat. No. 6,458,456 to Zainiev andUS20090054860 to Young et al.

It would be desirable to develop an absorbent article or an absorbentportion of an absorbent article that was flexible in use, that madeefficient use of peripheral areas of the absorbent portion and whichprovided a signal or communication to the consumer of level of usage orsaturation. In some absorbent articles it would be desirable to controlflow of absorbed fluids to certain areas of an absorbent article, suchas away from the transverse direction of an article, and in thelongitudinal direction of the absorbent article. It is also desirable tohave an absorbent article that could block or slow the flow of fluids totraditionally high risk leakage areas, such as in the wing or flapregions of child care products and feminine care hygienic pads/sanitarynapkins.

SUMMARY OF THE INVENTION

Objects and advantages of the invention are set forth below in thefollowing description, or may be learned through practice of theinvention. In one embodiment of the invention, an absorbent article hasa longitudinal and transverse direction, and includes a fluid permeabletopsheet, a fluid impermeable backsheet, an absorbent portion positionedbetween the topsheet and the backsheet, characterized in that theabsorbent portion includes at least superabsorbent yarn includingsuperabsorbent and fluid permeable components. The fluid permeablecomponents are for either distributing fluid along the yarn length,alternatively for retaining fluid, or for accomplishing both functions.

In an alternative embodiment of the invention, an absorbent articleincludes an absorbent portion that includes solely superabsorbent yarn.In a further alternative embodiment of the invention, an absorbentarticle includes an absorbent portion that further includes solelysuperabsorbent yarn and a carrier sheet. In a further alternativeembodiment of the invention, an absorbent article includes an absorbentportion having superabsorbent yarn which is selected from encapsulatedsuperabsorbent yarn, multi-layered encapsulated superabsorbent yarn,coated superabsorbent yarn, superabsorbent yarn made from superabsorbentcontaining fibers or filaments, and sliver-formed superabsorbent yarn.In a further alternative embodiment of the invention, an absorbentarticle includes an absorbent portion having a superabsorbent yarn thatis a multi-layered encapsulated superabsorbent yarn. In a furtheralternative embodiment of the invention, an absorbent article includesan absorbent portion with a multilayered encapsulated superabsorbentyarn, which yarn includes a topsheet layer and at least two otherlayers. In a further alternative embodiment of the invention, theabsorbent article includes an absorbent portion with superabsorbent yarnand an additional absorbent layer. In still a further alternativeembodiment of the invention, the absorbent article with superabsorbentyarn includes a shaping layer. In still a further alternative embodimentof the invention, the absorbent article with superabsorbent yarn in theabsorbent portion includes an additional layer between a topsheet and anabsorbent portion.

In still a further alternative embodiment of the invention an additionallayer between the absorbent portion containing superabsorbent yarn andthe topsheet defines one or more openings through which thesuperabsorbent yarn is visible through the topsheet. In a furtheralternative embodiment of the invention, the topsheet is translucent toallow the viewing of the superabsorbent yarn through the topsheet. Instill a further alternative embodiment of the invention, the absorbentarticle containing the superabsorbent yarn is either a feminine hygienearticle, an adult incontinence article, a baby or child care article, abandage, or a wiping towel. In a further alternative embodiment of theinvention, in the absorbent article containing superabsorbent yarn, thesuperabsorbent yarn is arranged in a superabsorbent portion as freesuperabsorbent yarn strands. In a further alternative embodiment of theinvention, in the absorbent article containing superabsorbent yarn, thesuperabsorbent yarn is arranged in a superabsorbent portion as a matrix.In a further alternative embodiment of the invention, in the absorbentarticle containing superabsorbent yarn, the superabsorbent yarn isarranged along peripheral edges of the article. In a further alternativeembodiment of the invention, in the absorbent article containingsuperabsorbent yarn, the superabsorbent yarn is arranged adjacent otherstrand materials. In still a further alternative embodiment of theinvention, the superabsorbent yarn is arranged such that an absorbentportion includes different strand densities of superabsorbent yarn perunit area, along the absorbent portion. In a further alternativeembodiment of the invention, in the absorbent article containingsuperabsorbent yarn, the superabsorbent yarn is arranged on the articlein a location separate from said absorbent portion. In a furtheralternative embodiment of the invention, in the absorbent articlecontaining superabsorbent yarn, the superabsorbent yarn is severed intomultiple pieces along at least one direction of said article.

In a further alternative embodiment of the invention, an absorbentarticle has a longitudinal and transverse direction, and includes anabsorbent portion consisting essentially of superabsorbent yarnincluding superabsorbent and fluid permeable components with the fluidpermeable components for either distributing fluid within the yarnlength or alternatively for retaining fluid. In still a furtheralternative embodiment, such an absorbent article includes encapsulatedsuperabsorbent yarn. In still a further alternative embodiment, suchsuperabsorbent yarn includes multi-layered encapsulated superabsorbentyarn having a layer which functions as a topsheet. In still a furtheralternative embodiment, the absorbent article consists essentially ofthe superabsorbent yarn and any yarn fastening components.

Those of ordinary skill in the art will better appreciate the featuresand aspects of such embodiments, and others, upon review of thespecification.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention is set forthmore particularly in the remainder of the specification, includingreference to the accompanying figures, in which:

FIG. 1 is a top plan view of an embodiment of the present invention inthe form of a feminine hygienic pad.

FIG. 2 is a cross-sectional side view of an alternative embodiment ofthe present invention of FIG. 1 taken along line X-X of FIG. 1.

FIG. 3A is a cross-sectional view of a superabsorbent yarn that may beused in the present invention.

FIG. 3B is a cross-sectional view of a different superabsorbent yarnthat may be used in the present invention.

FIG. 3C is a cross-sectional view of still a different superabsorbentyarn that may be used in the present invention.

FIG. 3D is a cross-sectional view of still a different superabsorbentyarn that may be used in the present invention.

FIG. 4 is a top plan view of another embodiment of the present inventionin the form of a feminine hygienic pad.

FIG. 5 is a top plan view of still another embodiment of the presentinvention in the form of a feminine hygienic pad.

FIG. 6 is a top plan view of still another embodiment of the presentinvention in the form of a feminine hygienic pad.

FIG. 7 is a top plan view of still another embodiment of the presentinvention in the form of a feminine hygienic pad.

FIG. 8 is a cross-sectional view of the embodiment of FIG. 7 taken alonglines Y′-Y′.

FIG. 9 is a top plan view of still another embodiment of the presentinvention in the form of a feminine hygienic pad.

FIG. 10 is a cross-sectional view of the embodiment of FIG. 9 takenalong lines Z-Z.

FIG. 11 is a top plan view of still another embodiment of the presentinvention in the form of a feminine hygienic pad.

FIG. 11A is a cross-sectional view of the embodiment of FIG. 11 takenalong lines X′-X′.

FIG. 11B is a top plan view of an alternative embodiment of the pad ofFIG. 1.

FIG. 11C is a top plan view of an alternative embodiment of the pad ofFIG. 1.

FIG. 11D is a top plan view of an alternative embodiment of the pad ofFIG. 1.

FIG. 11E is a top plan view of an alternative embodiment of the pad ofFIG. 1.

FIG. 11F is a top plan view of an alternative embodiment of the pad ofFIG. 1.

FIG. 12 is a top plan view of an alternative embodiment of the inventionin the form of a hygienic pad without wings, or liner.

FIG. 13A is an alternative cross-sectional view of FIG. 12 taken alongline Y″-Y″.

FIG. 13B is an alternative embodiment of the cross-sectional view ofFIG. 13A, without a backsheet 146.

FIG. 14 is a top plan view of an alternative embodiment of the inventionin the form of a feminine hygienic pad with signal windows.

FIG. 15 is a side perspective view of an alternative embodiment of theinvention in the form of a tampon.

FIG. 15A is a side perspective view of an alternative embodiment of theinvention in the form of a tampon.

FIG. 15B is a side perspective view of an alternative embodiment of theinvention in the form of a tampon.

FIG. 15C is a perspective view of an absorbent pledget ribbon to be usedin a tampon of the present invention, which is rolled prior tocompression.

FIG. 16 is a top plan view of an alternative embodiment of the inventionin the form of a diaper.

FIG. 17 is a top plan view of an alternative embodiment of the inventionin the form of a diaper.

FIG. 18 is a top plan view of an alternative embodiment of the inventionin the form of a diaper.

FIG. 19 is a top plan view of an alternative embodiment of the inventionin the form of a diaper.

FIG. 20 is a top plan view of an alternative embodiment of the inventionin the form of a diaper.

FIG. 21 is a side perspective view of an alternative embodiment of theinvention in the form of a diaper.

FIG. 22 is a top plan view of an alternative embodiment of the inventionin the form of a diaper.

FIG. 23 is a top perspective view of an alternative embodiment of theinvention in the form of a bandage.

FIG. 24 is an alternative embodiment of yarn placement in absorbentarticles of the invention.

FIG. 25 is an enlarged view of a portion of FIG. 24.

FIG. 26 is a top plan view of an absorbent wipe in accordance with theinvention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to present embodiments of theinvention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation ofthe invention and not a limitation of the invention. In fact, it will beapparent that modifications and variations can be made in the presentinvention without departing from the scope or spirit thereof. Forinstance, features illustrated or described as part of one embodimentmay be used on another embodiment to yield a still further embodiment.Thus, it is intended that the present invention covers these and othersuch modifications and variations as come within the scope of theappended claims and their equivalents.

For the purposes of this disclosure, the terms “superabsorbent polymer,”“superabsorbent” or “SAP” shall be used interchangeably and shall meanpolymers that can absorb and retain extremely large amounts of a liquidrelative to their own mass. Water absorbing polymers, which areclassified as hydrogels when cross-linked, absorb aqueous solutionsthrough hydrogen bonding with water molecules. A SAP's ability to absorbwater is a factor of the ionic concentration of the aqueous solution.SAPs are typically made from the polymerization of acrylic acid blendedwith sodium hydroxide in the presence of an initiator to form apoly-acrylic acid sodium salt (sometimes referred to as sodiumpolyacrylate). Other materials are also used to make a superabsorbentpolymer, such as polyacrylamide copolymer, ethylene maleic anhydridecopolymer, cross-linked carboxymethylcellulose, polyvinyl alcoholcopolymers, cross-linked polyethylene oxide, and starch graftedcopolymer of polyacrylonitrile. SAPs may be present in absorbentarticles in particle or fibrous form.

For the purposes of this disclosure, the term “sliver-formed yarn” shallmean yarn formed from a continuous strand of loosely assembled filamentsor fibers without a twist. The yarn itself has a twist, but the sliverdoes not. Sliver filaments or fibers are delivered by a card, comber ordrawing frame. The production of the sliver for the yarn, is the firststep that brings staple fiber into a form that can be drawn andeventually twisted into a spun yarn. Such yarn can include at leastsliver filaments containing SAP materials and sliver filaments notcontaining SAP materials, but including fluid permeable materials orcomponents that can assist in the distribution of fluid along the yarnlength.

For the purposes of this disclosure, the term “coated superabsorbentyarn” shall mean a fibrous or filamentous yarn that has been coated (viaany of a number of processes) along at least a portion of its externallyfacing surface with a superabsorbent polymer. The coating may behomogenous, heterogeneous or partial. The non-coated portion of the yarnincludes at least fluid permeable materials or components that canassist in the distribution of fluid along the yarn length.

For the purposes of this disclosure, the term “yarn” shall mean acontinuous length of interlocked fibers or filaments (as opposed toindividual filaments which are extruded in a continuous manner) suitablefor use in the production of textiles or nonwoven structures (woven ornonwoven), such as by sewing, crocheting, knitting, stitching, weaving,embroidery, rope making, adhesive, thermal or ultrasonic bonding. Theterm “yarn” shall include spun-based yarn which can be made by twistingor otherwise bonding staple fibers together to make a cohesive thread.The term yarn, may for the purposes of this definition includeribbon-like materials, and strand materials having variouscross-sectional shapes, such as round, oval, elliptical, square,rectangular and irregularly defined shapes. The term yarn, does notdescribe a planar sheet-like material.

Desirably in one embodiment, such yarns include staple fibers of betweenabout 0.05 and 6 inches. In a further embodiment, such yarns includebetween about 5 and 50 twists per inch. Desirably in another embodiment,such yarn has a decitex of between about 200 and 12000. Matrices madefrom such yarn may be created by nonwoven processes (thermo, adhesive orultrasonic bonding), weaving, knitting, tow, carding, sliver, or scrimmanufacturing methods.

For the purposes of this disclosure, the term “superabsorbent yarn”shall mean a yarn, as opposed to a fiber or filament, that includessuperabsorbent associated directly with its structure, such that thesuperabsorbent is attached to or contained within the yarn structure andthe yarn including at least other materials or components that are fluidpermeable and which assist in holding, wicking or distributing fluidalong the yarn length. The term “superabsorbent yarn” includessuperabsorbent coated yarn, that is a yarn that has been coated eitherby a homogeneous, heterogeneous or partial coating of superabsorbentpolymer, such as the yarns described in U.S. Pat. Nos. 5,264,251 toGeursen, 6,500,541 to Schoeck, Jr., and international referencesEP0784116 to Geursen, and WO97/43480 to Phillips which are herebyincorporated by reference in their entirety; sliver-formed yarn withsuperabsorbent particles, fibers or filaments contained therein such asthose described in EP 1198628 (U.S. Pat. No. 6,576,338) to Meijer whichis hereby incorporated by reference in its entirety; encapsulated yarnswith superabsorbent materials contained therein (either in a coreentirely made from SAP, or in core made of a combination of SAP andnon-SAP materials) surrounded by fluid permeable material, (such as Drefspun yarns) described in US20080096017 to Patrick and US20090176422 toPatrick, and which are hereby incorporated by reference in theirentirety; multi-layered encapsulated yarns having at least three layers,that is yarn having distinct components in multiple homogenous layers inthe Z direction of the yarn cross-section, with each layer provided withdifferent absorbency or liquid transfer/distribution functionality; andyarns produced from spunbond filaments with SAP internal components suchas those filaments described in US20050130540 to Crane, and which isincorporated by reference herein in its entirety. The superabsorbentyarns contemplated in the invention include either superabsorbentparticles or filaments as the superabsorbent components, and non-SAPfibers or filaments that are comprised of structures/compositions thatare fluid permeable, and can either retain fluid within their structures(as well as within the SAP particle and filament materials), or assistin transferring or distributing fluid along the length of the yarn toother fibers or filaments, or SAP materials. Such non-SAP components ofthe yarn can also assist in preventing the release of SAP materials toareas outside of the absorbent articles containing the superabsorbentyarn. The yarn may include other components to provide additionalfunctionality to the absorbent article, such as for example, pigmentsfor stain masking, fragrances for odor control, and color changechemistries for signal functionality.

Superabsorbent materials that can be used in the superabsorbent yarninclude but are not limited to modified hydrophilic polyacrylate, starchgrafted coploymers or cross-linked methylcellulose. Blending SAPmaterials either in a core for an encapsulated superabsorbent yarn or aspart of a sliver-formed yarn, can be accomplished by blending SAP withconventional fibers such as for example, cotton, rayon, flax, jute,knaf, ramie, polyester, polyolefin (for example bicomponent materials),polyamide, acrylic, polyethylene, polylactic acid (PLA) andpolytrimethylene terephthalate (PTT) fibers and blends thereof. Theencapsulation component of an encapsulated superabsorbent yarn can bemanufactured for example from fibers/filaments of cotton, rayon, flax,jute, knaf, ramie, polyester, polyolefin, polyamide, acrylic,polyethylene, PLA, PTT and blends thereof.

For the purposes of this disclosure, the term “free strandsuperabsorbent yarn”, shall mean a strand of superabsorbent yarn that iseither bonded to another non-yarn surface, or loosely positioned onanother non-yarn surface, without the yarn being bonded to anothersuperabsorbent yarn or contacted by another superabsorbent yarn strandthat is oriented in either the same or different direction.

For the purposes of this disclosure, the terms “matrix” or “matrices”shall refer to more than one superabsorbent yarn strand that has beenattached or otherwise bonded to another such strand orintersects/contacts another such strand in one or more directions, suchas in a grid-like structure, in which a series of transversely directedstrands are laid over a series of longitudinally directed strands.Bonding may be accomplished using any number of bonding techniques, suchas for example, adhesive, thermal, ultrasonic, needling or stitchbonding.

Side-by-side placed free strand superabsorbent yarn may include similaryarns (of dimension, denier or composition) or different yarns.Likewise, matrices made from the superabsorbent yarns may be made fromvarious denier fibers/filaments, various denier yarns, differentdimension yarns, or yarns of different compositions. Further, theplacement of yarn in matrices may be controlled to incorporate yarn inspecific localized bundles, fluid reservoirs on the yarn ends,non-uniform yarn crossings to control lateral spreading of fluid,greater yarn concentration in the article longitudinal direction ratherthan the transverse direction to utilize the farthest areas of absorbentportions, and non-straight lay down of yarn strands (such as sinusoidal(wave) or other zig-zag configurations) to enhance SAP surface area ofthe yarn in any given area. The fibers or filaments of such yarns may bestaple, continuous, mono or multi filamentous-based. The yarns may bedesigned to achieve differing attributes or functionality, such asdiffering dryness, intake, distribution and retention attributes, or toincorporate other functionality, such as for example signal, stainmasking, softness and odor control. The free strand superabsorbent yarnor yarn matrices may additionally be placed in only select areas of aplane or absorbent portion, or within multiple planes within a product.

The present invention relates generally to an absorbent articleincluding an absorbent portion for absorbing and retaining body fluidsor exudates. In many instances the absorbent article will includemultiple layers with a superabsorbent yarn either on, or between thelayers and positioned substantially along one or more directions of theabsorbent portion of the article, or along substantially one or moredirections of the absorbent article itself. The superabsorbent yarn canbe present in free strands or either woven or fashioned into a matrixbefore it is placed in an absorbent article, or alternatively it can beadhesively bonded or otherwise bonded as a matrix or free superabsorbentyarn strands in the article. The resulting open area of the absorbentportion of the article can vary by changing the superabsorbent yarndensity per unit area of the absorbent portion. Additionally, the typesof superabsorbent yarns themselves can be varied in an absorbentarticle, depending on product area needs. In some embodiments, theabsorbent portion of the article will be comprised of solely thesuperabsorbent yarn itself, for example, in strands or in adheredstrands that have been cut and fashioned/ adhered to themselves, in theshape of a traditional absorbent article. By using a yarn constructionby itself as the absorbent portion of an article, without supplementalfluid retention components or layers, the level of breathability andflexibility of the absorbent article can be increased. Further, it ispossible to direct exudates to specific regions of an article forefficient usage of the entire absorbent portion of the article, by useof the superabsorbent yarn.

The accompanying FIG. 1 depicts a top plan view of an absorbent article10 of the present invention as a hygienic feminine pad having aconventional elongated shape with generally rounded ends; however, theabsorbent article 10 may also be a panty liner, tampon, shield, diaper,training pant, adult incontinent garment, wipe, bandage, or any otherdisposable absorbent article known in the art, many of which areillustrated in later appearing figures. Moreover, the illustrated padabsorbent article 10 may have other shapes, such as hourglass, dogbone,elliptical, triangular or rectangular, and varying sizes and thickness,depending on the particular application desired. The absorbent article10 generally includes two end edges 12 and 14, two longitudinal directedside edges 16 and 18, and two optional wing or flap extensions 20extending from the longitudinal directed side edges 16 and 18. The wingsmay be integral with the pad structure, that is, extensions of layers inthe pad structure, or add-on features. The article 10 includes atopsheet or cover layer 30 which faces the skin of a user during use andwhich first receives body exudates from a user, and a backsheet orbaffle layer 32, which is normally positioned away from the skin of auser and often faces and contacts a user's undergarments oroutergarments. An absorbent portion/layer 35 is positioned between thetopsheet 30 and the backsheet 32 and includes at least superabsorbentyarn strands 36 as viewed through the partial cut-away hole in thefigure. In the figure, the free strands 36 are illustrated running inparallel lines along the longitudinal direction A of the article. Itshould be recognized that the strands could in an alternativeembodiment, also run in the transverse direction B of the article or acombination of the longitudinal and transverse directions. Further, theyarn strands 36 may run in a non-straight fashion, such as in a wave,zigzag or other configuration in either a uniform, nonuniform or randomdirection (intersecting or nonintersecting), or a combination of any ofthe above patterns. Such wavy or zig-zag patterns can provide moreabsorbent surface area than straight laid yarn strands. Thesuperabsorbent yarn strands 36 can be adhesively bonded directly to theinside surface of the backsheet 32 facing the topsheet 30, to the insidesurface of the topsheet 30, facing the backsheet 32, or as shown in FIG.2, which shows a cross-sectional view of an alternative embodiment ofthe article of FIG. 1 at line X-X, the superabsorbent yarn strands 36can be adhesively or otherwise bonded to a carrier sheet 37, which isitself bonded to an inside surface of the topsheet 30 or backsheet 32.In FIG. 1, no carrier sheet is illustrated, and the strands aresandwiched between the topsheet 30 and the backsheet 32. The carriersheet 37 may be positioned solely on one side of the superabsorbent yarnstrands (as illustrated in FIG. 2), or may partially or entirely envelopthe yarn strands, such that the yarn strands are sandwiched betweencarrier sheet layers. Additionally, more than one carrier sheet may bepositioned along one side of the yarn strands. Such carrier sheet(s) mayserve as a protective layer to isolate the superabsorbent yarn strandsor the superabsorbent components themselves, especially for preventingSAP from migrating to other areas of the product, but to still allowfluid to make contact with the yarn strands. Additional bondingtechniques may include needling or thermal bonding as well, forattachment of the yarn strands to the carrier sheets or adjacent layers.The carrier sheet may be constructed of traditional materials such as atissue or other nonwoven material, as are known in the art. In analternative embodiment, additional intermediate layers may be positionedbetween the yarn and carrier sheets and either the topsheet orbacksheet. Further, such superabsorbent yarn can wrap around such layersor through such layers to direct fluid in various directions within anarticle.

As can be further seen in FIG. 2, garment adhesive strips 38 or otherfasteners can be positioned along the longitudinal direction of theproduct central region and/or wings 20 for adherence of the article to auser's undergarments in use. Such adhesive strips 38 can be covered withadhesive release sheets 39 for covering the adhesive strips before use,and then removed at the time of use. The adhesive strips along thebacksheet center of the product would function to adhere the product tothe inside crotch region of a users undergarments or outergarments,while the adhesive strips on the wing backsheet areas would providetemporary attachment to the opposite side of the undergarment crotchregion once the wings had been folded about the side edges of theundergarments during use.

The topsheet 30 provides the absorbent article 10 with a liquid/fluidpermeable surface that contacts the user's skin. The topsheet 30 shouldprovide a comfortable, conforming interface with the user's skin bybeing flexible, compliant, and non-irritating to the skin. The topsheet30 desirably also transfers liquid/fluids quickly to underlying layersand remains dry and clean during use, effectively reducing oreliminating the feeling of rewet during use. In addition to being liquidpermeable, the topsheet 30 may also include apertures (not illustrated)for freely passing exudates with minimal absorption. The topsheet 30 maybe coated with a surfactant to further enhance permeability to theabsorbent portion 35 and reduce retention of fluids by the topsheet 30,or it may be coated or otherwise imbued with other skin-healthtreatments. The topsheet 30 may also include embossments (notillustrated) such as embossed channels, and arcuate embossments, tocreate an aesthetically pleasing surface, a particular product bendprofile or to further help disperse exudates passing through thetopsheet 30, or alternatively to slow their spread to the product sideedges. Furthermore, if so desired, these embossments may extend downinto one or more other layers of the product to enhance the fluidhandling properties of the product and may further serve to attach thetopsheet 30 to subjacent layers in the article.

The topsheet 30 may be constructed of any woven or non-woven materialwhich passes body fluids, yet remains comfortable to the user. Suitablenonwoven materials include, but are not limited to, hydroentangledspunlace materials, bonded carded webs (BCW) made from staple fibers,and spunbond webs. Apertured films are also suitable topsheet materials.Examples of suitable topsheet materials include rayon, bonded cardedwebs of polyester, polypropylene, polyethylene, nylon, or otherheat-bondable fibers, polyolefins, copolymers of polypropylene andpolyethylene, linear low-density polyethylene, and aliphatic esters suchas polylactic acid.

Other suitable topsheet materials include through-air bonded carded webs(TABCW) made from staple length fibers such as 25 gram per square meter(gsm) web made with 1.5 denier (d), polyethylene sheath, polypropylenecore bicomponent, 35-40 millimeter (mm) staple length fibers availablefrom FiberVisions Corporation with offices in Duluth, Ga., USA which areavailable under the trade designation ESC215. Topsheet materials mayalso comprise laminates of the above materials, and are desirably bondedto the inside surface of the backsheet 32. The topsheet 30 may also bemade from two or more different nonwoven or film materials. For example,the topsheet may be a multi-component material with a central section(not shown) running along and straddling the longitudinal centerline ofthe product with lateral side sections (not shown) flanking and joinedto either side of the central longitudinal section. The central sectionmay be made for example, from the aforementioned TABCW materials or itmay be made from a perforated film. The lateral side sections may bemade from a different fibrous nonwoven material which is joined to thecentral section. Such a dual material configuration is described forexample in U.S. Pat. Nos. 5,961,505 to Coe, 5,415,640 to Kirby and6,117,523 to Sugahara, which are hereby incorporated by reference intheir entirety. Such a dual material or bicomponent topsheet could offerthe feeling of dryness in the center longitudinal region, and a softfeeling along the side longitudinal regions. It is also contemplatedthat such dual material topsheets may include elastic components alongtheir side edges to lift up portions of the side materials during use,thereby forming physical barriers or a cupping feature of the product soas to fit closely to the body.

Topsheet materials with larger open areas are desired in one embodimentin order to provide visibility to the superabsorbent yarns beneath thelayer. As shown in the figures, it is desired that at least part of thetopsheet be translucent so as to allow a user of the product to observethe functionality of the superabsorbent strands (via a change in colorfrom dry to soiled yarn). Such may be further achieved by wide aperturesin the topsheet, which also allow exudates to flow quickly to thesuperabsorbent layers contained beneath the topsheet layer.

In the illustrated embodiments in FIGS. 1 and 2, the free superabsorbentyarn strands 36 make up solely the absorbent portion of the article.That is, there are no other liquid retention layers in the article. Insuch an embodiment, the superabsorbent yarn strands provide flexibilityto the article, that an absorbent sheet material would not. Further,such a configuration provides enhanced thinness and breathability to thearticle. Alternatively, the superabsorbent yarn strands 36 may be acomponent of the absorbent portion, which could also include cellulosicor synthetic fibrous wadding layer(s), a multilayered structure, such asone that includes a surge or transfer layer, a distribution layer or acombination thereof. These other layers while not illustrated, are wellknown in the art. These supplemental layers can be employed in theabsorbent article either in the same plane as the superabsorbent yarns,or alternatively in a plane above or below the superabsorbent yarns. Asurge or transfer layer provides an optional layer between the topsheetlayer and the absorbent core (portion). When present, a transfer layerwicks fluid passing through the topsheet layer and disperses the fluidto subjacent layers including the absorbent core. The transfer layer maycomprise any of the fibers, polymers and fibrous and film structuresmentioned above with respect to the topsheet material as well as anysurge materials as are readily available and well known to those ofordinary skill in the art. No matter which surge layer material is beingused, the surge or transfer layer can run the full length of the productor it may be shorter and strategically located in a specific area of theproduct. In addition, it can be a full width layer extending to thelongitudinal sides of the product or it may have a shorter width inwhich case it will generally be centered on the longitudinal centerlineof the product.

Further, as will be further explained, the superabsorbent yarns may alsobe part of one or more matrices, as opposed to being present in a freestrand configuration. For the purposes of this invention, in someembodiments it is desirable to minimize contact of individual yarnstrands (with one another) within an absorbent article, so as to preventinterference of SAP that may swell in one strand with fluid movement onanother strand. In this regard, in one embodiment, it is desirable thatthe percent contact/overlap of one strand with another separate strandbe between 0 and 100 percent, in at least one strand dimension. At 0%(no contact of individual strands), the discrete yarn strands allowfluid to be transferred within each individual strand such that theperformance of each strand does not impact that of the others. The spacebetween strands helps to drain fluid to the strands. At some overlap ofstrands (up to 100%), the strands can overlay each other in separatelayers. In such an embodiment, the yarn type on each layer can servedifferent functions such that they do not affect the performance of eachother. For example, a top layer can be for intake and distributionfunctionality whereas a bottom layer can be for containment/storagefunctionality.

The back sheet 32 may be peripherally joined to the top sheet 30 eitherdirectly or indirectly through intermediate layers, usually about theperiphery of the article. It provides the absorbent article 10 with aliquid impermeable and optionally vapor permeable surface that preventsexudates from completely penetrating the absorbent article 10 andsoiling the user's undergarment or outergarments. Ideally, the backsheet32 is soft, flexible, quiet, breathable, and may in one embodimentinclude some absorbent capacity on the side facing the absorbent portion35.

The backsheet 32 may be any suitable material known in the art, such asembossed and non-embossed thermoplastic films, nonwoven webs, laminatedtissue, and combinations of the foregoing. In one embodiment, thebacksheet 32 includes a non-woven material laminated to a microporousfilm with the nonwoven material forming a soft and comfortable exteriorsurface to the absorbent article 10. Desirably, such backsheet filmmaterials can haves a thickness of between about 0.03 to 0.07 mm anddemonstrate a water vapor transmission rate (WVTR) of between about 500to 2500 g/m2/24 hr. The backsheet can be transparent, translucent oropaque depending on the product needs. In order to enhance the signalingeffect of the superabsorbent yarns, and perception of thinness andbreathability of the product, transparent and translucent backsheetmaterials may be preferred. For aesthetic appeal, printed features mayalso be included on the backsheet.

Construction adhesives to be used in the products of the invention canbe those common to the art of personal care products. However, inproduct embodiments with apertured topsheets, non-tacky adhesives mightbe more desirable.

The absorbent portion 35 provides the operative material for collectingand retaining body fluids or exudates while remaining light and dryfeeling during use. The absorbent portion 35 should in one embodiment besoft, not stiff, and should retain its shape, even when wet. Theabsorbent portion 35 resides between the topsheet 30 and the backsheet32 and may be attached to either or both layers or to intermediatelayers such as the optional surge layer or carrier sheet to hold theabsorbent portion 35 in place and protect the absorbent portion 35 fromabrasion.

The absorbent portion of the absorbent article may be any structure orcombination of components with the superabsorbent yarns 36 which aregenerally compressible, conformable, non-irritating to the user's skin,and capable of absorbing and retaining bodily fluids. For example, theabsorbent portion with superabsorbent yarns may include an absorbent webof cellulose fibers, such as wood pulp fibers, other natural fibers,synthetic fibers, woven or non-woven sheets, scrim netting or otherstabilizing structures, additional superabsorbent materials separatefrom the superabsorbent yarns, binder materials, surfactants, selectedhydrophobic and hydrophilic materials, pigments, lotions, and odorcontrol agents, as well as combinations thereof. The absorbent portionmay be formed using various methods and techniques known in the art,such as dry-forming, air forming, wet-forming, and foam-forming, as wellas combinations thereof.

As previously stated, superabsorbent materials are well known in the artand may be selected from natural, synthetic, and modified naturalpolymers and materials. The absorbent portion 35 with superabsorbentyarns 36 generally includes superabsorbent material, with thesuperabsorbent material ranging from about 1-90 percent by weight of theabsorbent portion 35, depending on the application and desiredabsorbency. For example, the total absorbency may be about 200-900 gramsof 0.9% by weight saline for infant care products; whereas, the totalabsorbency for adult care products may be about 400-2000 grams of 0.9%by weight saline. For feminine care products, the total absorbency maybe within the range of about 7-50 grams of menstrual fluid. In oneembodiment, the superabsorbent is present in an amount of between about10 and 50 percent by weight of the yarn. Optionally, the absorbentportion 35 may include what is termed a core wrap (not shown) made fromtissue or a nonwoven sheet such as a spunbond or a meltblown nonwoven ora laminate of spunbond and meltblown layers, the purpose of which is toaid in retaining the superabsorbent yarn and yarn components neatlywithin the absorbent portion area and increasing both the wet and drystrength and integrity of the absorbent portion 35. The core wrap wouldenvelop all or a portion of the absorbent portion 35. Such a core wrapmay be useful to enclose superabsorbent yarn that containssuperabsorbent fibers or particles on the yarn outer surface.

Referring again to FIG. 1, the absorbent article 10 may optionallyinclude what are termed a pair of wings or flaps 20 extending laterallyfrom the central portion (or end portions for thong and overnightproducts, but not illustrated) of the product. Such wings or flaps 20are well known in the art and may be integrally formed from othercomponents of the article such as the topsheet 30 and backsheet 32, orfrom separate materials and then attached to the longitudinal sides 16,18 of the article 10.

The various layers of the absorbent article may be joined or not joinedto one another depending on the design criteria of the specific product.In this regard, any conventional joining techniques may be usedincluding, but not limited to, adhesives, bonding and embossingtechniques using heat and/or pressure, ultrasonic bonding, needling,stitching, hyrdoentangling, etc. In most instances, it is desirable toseal one or more layers together about the periphery of the product soas to reduce leakage of absorbed body fluids.

The superabsorbent yarns 36 are shown in FIG. 1 through a cutawayportion of the topsheet 30, but also through the topsheet 30 surfaceitself. In one embodiment, the topsheet is at least partiallytranslucent to allow a user to see the soiling of the absorbent portionalong the length of the superabsorbent yarns 36 during use. For thepurposes of this application, the term “translucent” shall mean theability of a user with legally defined sight, to view color changes ofthe superabsorbent yarn through the topsheet, when viewing the userfacing surface of the article unobstructed from a distance of betweenone and sixty inches. The visualization of the spread of fluid along thelength of the yarn is accomplished by the natural color change of theabsorbent materials in the superabsorbent yarn as body exudates areabsorbed by the yarn. In this fashion, a user of the product can clearlysee the level of product usage in anticipation of avoiding a potentialleak, without additional chemical signals. Alternatively, the topsheetmay be opaque or contain masking elements (such as pigments in thefibers or film) so as to avoid providing such information to users thatwould prefer not to see it.

As noted previously, various types of superabsorbent yarns may beemployed in absorbent portions of absorbent articles of the invention.For example, as shown in cross-sectional view of FIG. 3A, a yarn 50 offibers/filaments along its longitudinal body 51 may be coated along itssurface with superabsorbent particles 52 or fibers. The yarn is shown instylized format, but it should be understood that the yarn body itself51, may be twisted, such as in a traditional “S” or “Z” configuration orcrimped to further impart bulk or texture, or additional interstitialspace for fluid flow. In such a configuration, the central yarn body canbe made of fibers such as from fluid permeable materials and thesuperabsorbent fibers or particles can be adhered to the yarn byblending, chemical binder, charge attraction or other traditionalbonding method. The non-SAP fibers/filaments are desirably fluidpermeable such that they either hold fluid, or distribute fluid alongthe yarn length.

Alternatively, as can be seen in FIG. 3B, the superabsorbent yarn 60 caninclude an outer fluid permeable layer 61 which encapsulates a centralsuperabsorbent material containing core 62. In such an encapsulatedsuperabsorbent yarn, or a yarn made from encapsulated superabsorbentfibers, the superabsorbent material is less likely to migrate out of theyarn to the other portions of the article or to the consumer's skinsurfaces. In such an embodiment, the need for a separate carrier layer37 is reduced, especially one that completely envelops the yarn on bothsides. Further the outer fluid permeable layers of the yarn can act as afluid intake or distribution layer before bulk fluid is locked into thesuperabsorbent core material of the yarn or filaments in the yarn. Thenonwoven outer layers can also be tailored to achieve particular fluidhandling properties, by selection of porosity, fiber type, fiber size,varying fiber twists between the outer and core layer(s) etc. Forexample, fibers may be varied depending on the ultimate objective ofabsorbing urine waste, bowel movement waste, menstrual waste or woundexudates. Fiber affinities to various fluids may vary depending oncomponents of the fluid to be absorbed, such as affinities toproteinaceous fluids or ion/salt containing fluids. Further, the cottoncount of any yarn that is selected to be part of a matrix (such as awoven pattern) will also impact the flexibility of the yarn. Therefore,if matrices of superabsorbent yarn are to be used in a product, one ormore types of matrices can be used with variations in size, open area,core composition, outer layer composition and layering to providedifferent levels of fluid handling and body fit at different locationsin an absorbent article. Such varying matrices can be placed in eitherthe same plane/layer or differing planes/layers within the absorbentarticle. For example, in any given plane of an absorbent portion of anarticle, a central region can comprise a rapidly wicking yarn, while theedges of the plane can be comprised of yarns with better fluid retentioncapabilities, that is the ability to hold onto the absorbed moisture,rather than focusing on initial bulk absorbency characteristics.Depending on the desired fluid handling features of the article, it isenvisioned that the absorbent matrices can also include absorbent yarnswithout SAP, such as yarns from polyester, rayon and nylon materials,but in combination with such SAP yarns. Further, traditional absorbentmaterials can be used in conjunction with the superabsorbent yarns, suchas airlaid materials, through air bonded carded webs, SAP planar sheets,hydroentangled materials, and chemically bonded carded webs. As with theyarn of the previous figure, the yarn of FIG. 3B may include varyingtwists, either in its entirety or between layers, or additionalcrimping.

Alternatively, as can be seen in FIG. 3C, the superabsorbent yarn 70 caninclude multiple layers in the Z cross-sectional direction (depthdirection). Such outermost layers would be fluid permeable, with eachlayer itself functioning as a traditional layer in an absorbent article.For example, the outermost layer 71 can be comprised of fibers thatwould normally make up either a topsheet or initial surge or transferlayer of an absorbent article. Such outermost layer can be made oftraditional topsheet layer fibrous materials if the absorbent articlecontaining the yarn does not include a separate topsheet layer (asdescribed further in FIGS. 13A and 13B). The outermost layer 71 canalternatively be made of fibers that would normally make up either asurge layer or transfer layer, if the article containing the yarn wouldinclude a separate topsheet layer. In this fashion, as fluid is drawninto the yarn, it would pass through a traditional surge or transferlayer along the yarn's entire length. Beneath the surge layer 71 (ortopsheet layer as the case may be), at least one interior absorbentlayer can be positioned along the yarn's length 72. Such absorbent layercan be positioned continuously along the yarn's length ordiscontinuously along the yarn's length. Finally, within the center ofthe yarn, a superabsorbent containing secondary core can be positioned73 along the yarn's entire length, or alternatively discontinuouslyalong the yarn's length. In this fashion, a self-contained absorbentsystem can be configured into a single yarn strand that can be cut to adesired length and placed strategically in an absorbent article of thepresent invention. Such absorbent outer layers 72 can be comprised oftraditionally used absorbent fibrous materials. Such multiple layeredyarns can be manufactured using Dref spinning systems as thosepreviously noted herein. It should be recognized that several absorbentand other functional layers may be employed in such yarns to achieve thedesired level of absorbency and distribution along the entire yarnstrand length. Such layering would of course be dependent on the type ofbody exudates being absorbed and the type of absorbent article desired.For example, an absorbent system designed to wick menses may employdifferent materials than one designed to wick urine or bowel movements.As with the previous figures, such yarn may also include a variety oftwists depending on layer, as well as crimping.

As can be seen in FIG. 3D, such superabsorbent yarn strands 80 mayinclude surface treatments along the Y-Y axis, depending on yarnplacement in an absorbent article. For example the upper surface thatfaces a user may include a hydrophilic finish 81, while the lowersurface finish 82 facing away from a user towards a garment, may employa hydrophobic surface treatment. Such surface treatment materials areknown in the absorbent art and will not be further described.

While the superabsorbent yarn strands 36 are shown in a parallel linearconfiguration along the absorbent article's longitudinal direction inFIG. 1, it should be appreciated that such a configuration is meant forexample only. Other configurations may be more desirable, depending onproduct usage. For example, as seen in the top plan view shown in FIG.4, an alternative embodiment of a feminine hygienic article (pad)includes such visible free superabsorbent yarn strands 90 positionedbetween a topsheet and a backsheet, but in a star-burst pattern suchthat fluid is wicked to all perimeter areas of the article from acentrally located fluid deposition area 92. Some of the strands 90 wouldbe cut of a longer length to accommodate the longer distances to theouter periphery of the product. As can be seen in the top plan view of afeminine hygienic article of FIG. 5 showing a further alternativeembodiment, in an alternative, such visible superabsorbent yarns can beconfigured into a grid-like matrix along the product between thetopsheet and the backsheet, so as to wick exudates across both thelongitudinal 95 and transverse 100 yarn directions of the product. Ascan be seen in a further alternative embodiment of a feminine hygienicarticle of FIG. 6, visible superabsorbent yarns can be positioned alongthe product periphery 110 between the topsheet and backsheet such thatthey serve as an outer barrier or boundary to prevent leakage of bodyexudates prior to the fluid reaching the product edges. Such aconfiguration could also employ the superabsorbent yarn 112 surroundinga traditional absorbent wadding layer 113, with both of the traditionalabsorbent layer and the superabsorbent yarns being positioned in thesame plane between the topsheet layer and the backsheet layer(s). Asnoted previously, in some embodiments, the absorbent article may employelastic features to elevate portions of the article. As can be seen inFIGS. 7 and 8 (FIG. 8 showing a cross-sectional view of FIG. 7 takenalong line Y′-Y′), the feminine hygienic article employs a traditionalwadding absorbent core 119. Such wadding can be in the form ofcellulosic materials, airlaid materials, TABCWs, SAP sheets or acombination thereof. The topsheet includes both visible superabsorbentyarn strands 120 and 122 to serve as fluid barriers, and also elasticstrands 124, to serve as elevating means to raise the barriers along thearticle side edges during use. Traditional pre-tensioned elasticstrands, or liquid shrinkable elastic strands may be employed for thispurpose, as are known in the personal care article art. Such strandswould be adhered to either the underside or topside of the raisedtopsheet surface using traditional bonding methods, or alternatively,may be bonded between multiple layer topsheets in these areas.

Referring to FIGS. 9 and 10 (10 which is a cross-sectional view of FIG.9 taken along line Z-Z), in an alternative embodiment, a femininehygiene article shown in top plan view contains a stabilizing member 129for controlling the contour and bunching of the product during use,thereby providing greater stability of the product. The stabilizingmember or shaping layer, as it is sometimes called, is desirablypositioned either between the superabsorbent yarns 125 of the absorbentportion and the backsheet layer (with the superabsorbent yarnspositioned beneath the topsheet) as illustrated, or alternatively, withthe superabsorbent yarns beneath the stabilizing layer, which is closerto the topsheet (not illustrated). In the case of FIG. 9, the shapinglayer is in the shape of a butterfly. A common problem with absorbentarticles such as sanitary napkins is their tendency to bunch and ride upinto the contours of the body including the buttocks and the vaginalarea during use. Bunching reduces the effective surface area of fluidcapture, increasing the likelihood of fluid leakage and staining ofundergarments/outergarments. As the net-like matrices of the absorbentyarns of the present invention are highly flexible, the pad may becomemore susceptible to body pressure and movement, resulting in this typeof bunching. In order to overcome this possibility, the addition of astabilizing member provides extra support. The shaping layer maycomprise one or more layers of materials that are positioned towards thelongitudinal and transverse center lines. Such shaping layer can berigid and fluid impermeable, but can also be fluid permeable. Suchstabilizing layer can be manufactured from a variety of materials, suchas for example, airlaid materials, meltblown materials, SAP sheets,fluff mats, foams, films, bulky bonded carded web materials or othermaterial or combination of materials, which provide sufficient integrityto relieve bunching. While placement of such a layer can be anywhere inthe product, it should be positioned so as not to negatively impactfluid handling attributes. Such a shaping layer can be of any size orshape although it is preferably shaped to preserve the openness of theabsorbent portion. It is in one embodiment, die cut. One desirableshaping layer is an airlaid cut-out material, of between about 60 gsm to200 gsm, that is narrowest in its center, so as to retain an openness tothe absorbent portion as shown in the figure. Such a shaping layer canbe either absorbent or non-absorbent.

In a further alternative embodiment of a feminine hygiene article, asshown in FIGS. 11 and 11A, an open area at the product center is createdby a hole-like structure 133 defined by either an upper absorbent layeror fluid transfer/surge layer 132, which is situated beneath a topsheet131 and above superabsorbent yarn strands 134. As can be seen in FIG.11A, which is a cross-sectional view of FIG. 11 taken along line X′-X′,such yarn is also situated upon a carrier layer 136 that is positionedbetween the topsheet 131, and the backsheet 135. In such an embodiment,the hole 133 contained within an upper surge or transfer layer helps tofurther direct exudates down to the absorbent portion, made from freesuperabsorbent yarn strands 134. It also helps to focus the user'sattention on the strands as the upper absorbent layer or fluidtransfer/surge layer 132 is opaque in one embodiment, preventing viewingof the yarn in areas outside of the hole. It should be recognized thatthe upper absorbent layer or fluid transfer/surge layer 132 can beformed of absorbent or surge materials known in the art.

In still a further alternative embodiment, as shown in FIG. 11B, afeminine hygiene article is illustrated in top plan view having acentrally placed supplemental absorbent layer 137 in an ovalconfiguration, positioned beneath the topsheet and above parallel freesuperabsorbent yarn strands. In this embodiment, a hump is created bythe supplemental absorbent layer 137 along the central longitudinal andtransverse axis, so as to allow for closer contact of the product in thevaginal vestibule of a female consumer during use. It should berecognized that the hump or raised portion can be of any shape and ofmaterials known in the art for absorbent layers.

In still a further alternative embodiment of a feminine hygiene article,as illustrated in FIG. 11C, a traditional absorbent layer 138 ispositioned between a topsheet and a backsheet. However, a strand ormultiple strands of superabsorbent yarn 139 are positioned within thesame plane as the traditional absorbent layer, but surrounding theperimeter of the traditional absorbent layer 138. In this fashion, anouter wall of absorbent protection is provided in conjunction with atraditional absorbent layer 138.

In still a further alternative embodiment of a feminine hygiene article,as illustrated in FIG. 11D, different types of superabsorbent yarns canbe positioned in either the same plane or different planes within anabsorbent article. For example, rapidly absorbing superabsorbent yarncan be placed along the longitudinal centerline of a product 140, whilegreater retention capacity superabsorbent yarn 141 can be placed closerto the longitudinal side edges of an article, for example in a layerbetween the topsheet and backsheet of the article.

In still a further alternative embodiment of a feminine hygiene article,as illustrated in FIGS. 11E and 11F, different densities ofsuperabsorbent yarns can be positioned in different regions of a productto direct fluid to desired locations. For example, as seen in FIG. 11E,higher densities per unit area of superabsorbent yarn 142 can bepositioned along a product's edges (between the topsheet and backsheet)in order to move fluid away from the sides to the ends 143 of a product,which would have the highest density of yarn in the product per unitarea. Alternatively, as seen in FIG. 11F, higher densities ofsuperabsorbent yarn can be positioned in a product center 144, between atopsheet and backsheet, to move fluid away from the center to theproduct ends 145.

In still a further alternative embodiment of the invention, as seen inFIG. 12, which illustrates a top plan view of a hygienic feminine careliner having a carrier or backsheet layer 146 and parallelsuperabsorbent yarn strands 147 adhered across the transverse directionof the liner. As can be seen in FIG. 13A, which illustrates analternative embodiment of the liner of FIG. 12 and in particular, anenlarged view of a cross section of the alternative embodiment of FIG.12 taken along line Y″-Y″, the superabsorbent yarn strands can bestacked in layers 147 upon the liner backsheet 146. In this fashion,they can be adhesively adhered to each other and the backsheet/carriersheet, without a separate topsheet present. If an encapsulated yarn isused as the superabsorbent yarn component, the encapsulated yarn caninclude an outer ring of material (as previously described) whichfunctions as a topsheet, thereby eliminating the need to have a separateand distinct topsheet. In still a further alternative embodiment of theliner of FIG. 12, as can be seen in FIG. 13B, the carriersheet/backsheet 146 can itself be eliminated, and the liner itself canbe formed only from stacked superabsorbent yarn strands 147 bonded toeach other 148 as a composite. The yarn strands can be cut to a desiredlength to mimic the length of a liner either before or after they areadhesively adhered, for example, to each other. The yarn strands can beadhesively bonded using an adhesive which maintains its flexibility upondrying, or alternatively, using intermittent applications of adhesive soas to not restrict yarn swelling.

In still a further alternative embodiment of the invention, a top planview of a feminine hygiene article in the form of a pad is shown in FIG.14. In such figure, a transfer or surge layer 150 is positioned betweena translucent topsheet and an absorbent portion. Such surge layer 150 isopaque in one embodiment, shielding or masking the staining of lowerlayers that may become discolored from body exudates absorbed from auser wearing the article. Numerous perimeter openings or windows 151,152, 153, and 154 are defined by the surge layer 150. A matrix ofsuperabsorbent yarn 160 is situated beneath the surge layer and betweenthe surge layer and the backsheet. The matrix of superabsorbent yarn 160is only visible to the consumer through the translucent topsheet and thesurge layer 150 via the openings, such that the consumer can easilyobserve spread of absorbed exudates in the article that were originallydeposited in the central area of the pad, and recognize when theabsorbed and spreading exudates are approaching or have approached thelongitudinal and transverse side edges of the article, thereby takingaction to change the product before potential exudate leakage, andsubsequent staining of the user's undergarments. In such an embodiment,the mere color change of the superabsorbent yarn, either in actual colorchange or shade change as a result of insult, will provide a passivevisual notification or signal of a pending leak. It should be understoodthat such openings can be present in any number, and in a variety ofselected perimeter locations. For example, such openings may only bepresent adjacent the wings 152, 153 in the product transverse directionor only at the ends 151 and 154.

In still a further alternative embodiment of the invention, a side planview of a feminine hygiene article, in the form of a tampon absorbent isshown in FIGS. 15, 15A and 15B. In the FIG. 15, the tampon is primarilycomprised of a compressed absorbent wadding 170, around which thesuperabsorbent yarn 171 is wrapped. Alternatively, the superabsorbentyarn may be part of the withdrawal string 172 of the tampon. The tamponmay or may not include a cover sheet over the superabsorbent yarn toassist in keeping the superabsorbent from falling from thesuperabsorbent yarn (depending on yarn type). In FIG. 15A, the tamponcan include discrete placements of superabsorbent yarn on the tampon,such as on the upper insertion end 173 or lower withdrawal end 174 ofthe tampon. In such a fashion, the superabsorbent yarn can serve as afinal fluid barrier to prevent leakage of menstrual fluids from thetampon either while in use, or at the time of withdrawal. As can be seenin FIG. 15B superabsorbent yarn can be formed in a tow-type fashionrather than as part of a secondary absorbent material, such that thetampon itself is comprised of numerous superabsorbent yarns 175 that areeither covered or not, by a separate cover sheet 176 and which are heldin place at the tampon withdrawal end by a retention element 177, suchas a band, or compressed region. While the superabsorbent yarn isillustrated on the outside surface of the tampon in FIGS. 15 and 15A, itcan just as easily be positioned along the inside of the tampon. Forexample, as seen in FIG. 15C which shows a roll of a tampon absorbentpledget ribbon that has the superabsorbent yarn 178 wrapped with theabsorbent sheet of the tampon into a roll 179 prior to compression, andwhich would subsequently be included on the inside of the tamponabsorbent following compression and tampon formation.

In still a further alternative embodiment of the invention, a top planview of a diaper 180 is illustrated in FIG. 16. The diaper includes twowaist regions 181 and 182 connected via a crotch region 184 and havingfasteners 183 along the side edges of one waist region 181. The diaperincludes a topsheet and a backsheet, which sandwich an absorbent core185. As with the previously described feminine hygiene articles, thetopsheet and backsheets can be manufactured from materials known in theart and the topsheet can in some embodiments be translucent if desired.The core can similarly be manufactured of absorbent materials known inthe art. Positioned on or in the absorbent core are superabsorbent yarns186 strategically placed along the absorbent core peripheral edges toserve as a last barrier against exudate leakage. As with the previousembodiments, the superabsorbent yarns can be affixed to a separate corelayer, solely comprise the core, or affixed to a carrier sheet. As seenin FIG. 17, which illustrates an alternative diaper embodiment to thatshown in FIG. 16, the absorbent core may include different functionalsuperabsorbent yarns placed adjacent one another, 186, 187. For example,some of the superabsorbent yarns may be designed to absorb and retainrelatively large amounts of exudates, while others may be designed torapidly absorb exudates, but not retain as much. As seen in FIG. 18,which illustrates still a further alternative diaper embodiment to thatshown in FIG. 16, regions of relatively high density superabsorbent yarnmay be placed in the waist areas 189 to stop leakage of exudates at thewaist areas, while crotch core regions between the waist areas can havedirectionally parallel superabsorbent yarns 188 to transport exudates tothe outer regions of the absorbent core in the waist areas. As seen inFIG. 19, which illustrates still a further alternative diaper embodimentto that shown in FIG. 16, such diaper may include side flaps (or crotcharea walls) 190 which traditionally include elastic components (notillustrated) in order to contain body waste in a defined area.Superabsorbent yarn 191 may be placed on or within the side flaps toserve as a final absorbent barrier to prevent exudate leakage. In asimilar fashion, as can be seen in an alternative diaper embodiment inFIG. 20, the diaper may include elastic waist regions 192 which assistin diaper fit and comfort. Within the waist regions, superabsorbent yarn193 can be placed to serve as an exudate leakage barrier. In a similarfashion, as can be seen in an alternative diaper embodiment in FIG. 21shown in side view, the diaper may include elastic detachable sideportions 194 and 195 which also assist in diaper fit and comfort. Withinthe side portions, superabsorbent yarn 196 can be placed to serve as anexudate leakage barrier. Finally, in a similar fashion, as can be seenin an alternative diaper embodiment in FIG. 22, the diaper may includesupplemental absorbent barriers in other peripheral locations, such ason or in the fastener systems 197 or in the waist regions adjacent thefasteners 198.

In still a further alternative embodiment of the invention, as can beseen in the perspective view of FIG. 23, the superabsorbent yarn can beplaced on a bandage substrate 200 along the central region, in the formof a matrix 210. Such matrix can be bonded to the substrate utilizingknown bonding methods. Desirably the substrate 200 is of a liquidimpermeable material, such as a single or multi-layered film, ornonwoven laminate, as are also known. The bandage may or may not includea fluid permeable cover layer 211. Such bandage may be capable of beingwrapped around a body part, or adhesively attached to a body part viaeither separately attached adhesive tape or topically applied adhesive212 on the surface of the substrate.

In other alternative embodiments, as are illustrated in FIGS. 24 and 25,the superabsorbent yarn 250 can be placed in an absorbent article insevered pieces, such as are illustrated in the figure. Such yarn piecescan provide additional surface area for absorption and allow forexudates to be absorbed also from numerous yarn ends as desired.

In an embodiment illustrated in FIG. 26, the superabsorbent yarn can beplaced as a matrix upon, or within an absorbent towel substrate 260, toboth provide resiliency and wet strength to the towel substrate. Byproviding the yarn in a transversely and longitudinally directed matrix261, the absorbed fluids can be directed to many areas of the towel, formore efficient usage of the entire towel. As previously described, thesuperabsorbent yarn can be designed to absorb and retain differentfluids depending on the ultimate absorbency objectives of the towel.

Not being bound to theory, it is surmised that the helical and twistingnature of superabsorbent yarns, and in particular encapsulated yarns,influences the absorbency and wicking properties of the yarns to achievethe desired absorbency characteristics in the consumer productsdescribed herein. In addition to the choices of materials in the yarn,such as the choices of filaments for internal and external layers, thevariations of twist densities and directions of twists between layersmaking up the yarn macrostructure (as opposed to individual fiberstructure making up the yarn) will influence the yarn's ability to movefluid along the yarn length and into the core regions (if distinct coresare present). It has been found that the yarn's helical structuregenerates local helical fluid movement along the dimensions of theabsorbent article. While previously utilized linear fluid channelsprovide limited volume of fluid movement, helical channels may provide abalance between linear speed and increased volume of fluid movement,especially when combined with the retention properties of superabsorbentcomponents.

Fluid is traveling both radially into SAP components of the yarn, andhelically along channels created around twisted filament or fibers. Asfluid reaches the SAP components, the SAP expands, causing changes influid pathways, altering the void volumes at areas of insult.

Those skilled in the art will recognize that the present invention iscapable of many modification and variations without departing from thescope thereof. Accordingly, the detailed description is meant to beillustrative only and is not intended to limit, in any manner, the scopeof the invention as set forth in the appended claims.

What is claimed is:
 1. An absorbent article having a longitudinal andtransverse direction, and comprising an absorbent portion consistingessentially of free strand superabsorbent yarn including superabsorbentand fluid permeable components, said fluid permeable components foreither distributing fluid within said yarn length or alternatively forretaining fluid, wherein said free strand superabsorbent yarn isencapsulated superabsorbent yarn, and in which absorbent article thereare no other fluid retention layers.
 2. The absorbent article of claim1, wherein said encapsulated superabsorbent yarn is comprised ofmulti-layered encapsulated superabsorbent yarn having at least twolayers including an outer layer which functions as a topsheet.
 3. Theabsorbent article of claim 1, wherein said absorbent article consistsessentially of said absorbent portion.
 4. An absorbent article having alongitudinal and transverse direction, and comprising a fluid permeabletopsheet, a fluid impermeable backsheet, an absorbent portion positionedbetween said topsheet and said backsheet, characterized in that saidabsorbent portion comprises superabsorbent yarn including superabsorbentand fluid permeable components said fluid permeable components foreither distributing fluid within said yarn length or alternatively forretaining fluid, and wherein said absorbent article further includes anupper layer located between said fluid permeable topsheet and saidsuperabsorbent yarn, said upper layer defining a hole-like structure fordirecting body exudates down to the absorbent portion, and through whichsaid superabsorbent yarn is visible.
 5. The absorbent article of claim4, wherein said upper layer is opaque such that said superabsorbent yarnis prevented from being viewed outside of said hole-like structure. 6.The absorbent article of claim 4, wherein said article has an articlecenter, said hole-like structure is located at said article center, andfurther, wherein said superabsorbent yarn is free strand superabsorbentyarn.
 7. The absorbent article of claim 4, wherein said article upperlayer has a perimeter, and wherein said upper layer includes numeroushole-like structures about the upper layer perimeter through which saidsuperabsorbent yarn is visible.